Svenska KVP 2016, Gøteborg, 2016-10-21 Høytemperatur …€¦ · Market and motivation HeatUp...

Teknologi for et bedre samfunn

Svenska KVP 2016, Gøteborg, 2016-10-21

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Høytemperatur varmepumper – HeatUp

Petter Nekså[email protected] Energi AS

Also,

Adjunct Professor at NTNU, Dept of Energy and process engineering

Visiting Professor at Doshisha University, Energy Conversion Research Center, Kyoto

mailto:[email protected]


Outline of HeatUp

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About the HeatUp project Partners Market and motivation HeatUp goal and focus

Kigali amendment of the Montreal Protocol Basics about high temperature heat pumps Working fluids possibilities Currently focussed activities Example steam MVR Related activities

DRYficiency HighEFF

Conclusions


HeatUp scope

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Utilisation of surplus heat from industrial processes Surplus heat from 30°C to 50°C and higher Heat pumping for delivery at 80°C to 180°C (250°C)

Solution depending on temperature requirements and energy demand of the industrial processes of the partners

Teknologi for et bedre samfunn 4

Focus on efficient energy use and how to meet the increasing energy demand in an environmentally benign wayEnd users: Statoil Oil and gas industry Statkraft Varme District heating Hydro Aluminium Aluminium, producer and supplier of al-products Vedde/TripleNine fish oil- and forage producer Mars Petcare producer of forage, chocolates and beverages TINE SA producer of diary products

Represents three of the largest industry sectors in Norway:Oil and gasMetal productionFood technology

Vendors: Hybrid Energy Cadio AS Epcon Evaporation Technology

KPN project supported by the EnergiX program at RCN (Project no 243679/E20)

Research partners: SINTEF Energy Research NTNU, Energy and process engineering

HeatUp partners


HeatUpmotivation(Germany)

Reference: Wolf, S., et al. (2014). Universität Stuttgart



HeatUpmotivation(Europe)


HeatUpmotivation


20-25.000 plants of 1 MW capacity (24/7)Potential 25% of this?


HeatUp goal and focus

Goal Utilisation of high temperature heat pumps in the

industry to reduce primary energy consumption (el and fossil) reduce greenhouse gas emissions

Reduce dependence of fossil fuels

Focus Satisfy the needs in the partner industries Push heat delivery temperatures to 180'C (250'C) Natural working fluids (HCs, NH3, H2O and CO2)


HFCs to be phased down according to Kigali amendment

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Natural refrigerants, a long term option, avoiding uncertainty of 4th

generation HFCs (HFOs)


What COPs can realistically be obtained

Assumptions COP variation with temperature lift and heat absorption temp 60% of Carnot efficiency (COP=ηcarnot× COPcarnot)

0

5

10

15

20 30 40 50 60 70 80 90 100

COP

Temperature lift [K]

120 °C

100 °C

80 °C

60 °C

40 °C


High temperature heat pump challenges

High discharge temperatures Motor cooling Degradation of lubricant, if not oil-free Suction temperatures often above ambient temperatures Acceptable temperature lifts, available heat sources Adaptation to actual heat source and sink characteristics Heat exchange with demanding fluids under challenging

conditions Cost competition to alternative means of heat supply


Simplified comparison of fluids

*Evaporating enthalpy and thermal conductivity

Property Water Ammonia Propane Butane Isobutane Pentane CO2 R134a R1234yf

Critical temperature 374 132 97 152 135 197 31 101 95

Normal boiling point 100 -33 -42 0 -12 36 - -26 -29

Specific volume Very high

Thermal properties* Very good Good

Safety

Environmental impact

Price


Propane – butane cascade heat pump Water heating to 120'C

Steam - water MVR – steam up to 150'C for drying

Ammonia – water District heating utilising a high

temperature absolute heat source

Currently focussed activities

Wet product

Steam

Drying system

Direct or

indirect

Dry product

Excess vapour

Condensate / cold steam


Wet product

Steam

Drying system

Direct or

indirect

Dry product

Excess vapour

Condensate / cold steam

Re-heating of steam

Drying system

Direct or

indirect Condensate / cold steam

Steam

(Oil, gas or electricity)

Excess vapour

Example – MVR steam based drying system


Example – MVR steam based drying system

Use excess vapour as heat sourceNeed to compress it to a higher pressure level (= higher

temperature level for condensing) Re-heating of process steam to initial conditions Reduce the specific energy consumption from 0.8 to 0.2 kW per

kgwater

Energy saving potential of up to 80% Electricity to run the compressors is the main primary energy

input into the system MVR-concept is well known and established Return of investment depends on energy prices and system

cost


Compression Technology for MVR systems

Type Compressor Turbocompressor Centrifugal Fan Roots Air Blower

Pressure Ratio (single stage)

<5 ＜2 ≤ 1.3 ≤ 1.5

Temperature Rise Single stage max. 40 °C

Single Stage max. 20℃

Single Stage max.7℃ Single Stage max.~10℃

Max. Flow Rate 120 t/h 100 t/h 120 t/h 3~5 t/hImpeller Type Screw or piston

compressor Three-dimension Flow, Centrifugal Type

Two-dimension Flow, Centrifugal Type

Two-impeller or Three-impeller, Volume Type

Impeller Material Stainless Steel Stainless Steel or Titanium Steel

Stainless Steel Cast Iron, Nickel Plating or Nickel-Phosphorus

Manufacturing Cost High High (medium?) Low Quite LowPhotos

Realization of Rotary Speed

Direct or gear drive Gear Increase Direct Connection with High-speed Motor

Synchronous Gear

Range of Rotary Speed

Commonly less than 4000 r/min

5000~40000r/min Commonly less than4000r/min

150~3000r/min

Thin Oil Lubricating System

Yes, oil separator necessary

Yes, Not Contacted with Medium at all

Unavailable for the Majority

Gear Oil and Grease Lubrication, Contacted with Medium

Service Life 5 years Three-year Three-year Nearly One Year

Overview of available compression technology for steam compression (MVR)


Turbo-charger for Superheated Steam: Pressure ratio 2.4 per stage; Temperature increase from 100 to 150 °C, about

25K per stage Swept volume is 0.2 m3/s Speed: rpm up to 86000 Volumetric efficiency 0.7 - 0.8 Isentropic efficiency 0.8 Specific weight: 20 kWheat / kgmetal

Alternative technologies: Screw compressors (1 stage) "Roots" blower + fan for SHS (5 stage)

New Compressor Technology


Compressor efficiency map


Used prim. energy, kW

Steam regeneration, kW

Excessheat, kW

COP total, -

COP steam, -

DryingefficiencykWh kg-1

Traditional scheme (oil)

1638.6 1556.6 1542.6 1.89? 0.95 0.79

Open system(HP)

405.4 1556.6 371.0 4.75 3.84 0.19

Closed system(HP)

470.2 1556.6 406.5 4.17 3.31 0.22

Example: MVR system (3 stage MVR 100-180°C)


Case 1 Germany

Case 1 Norway

Case 2 Germany

Case 2 Norway

Pressure Inlet Bara 1.0 1.0 1.0 1.0Temperature Inlet Deg C 110 110 110 110Pressure Outlet Bara 5.0 5.0 10.0 10.0Steam Flow Rate (inlet)

kg/h 2,000 2,000 2,000 2,000

Electrical Power (system)

kWe 304 304 461 461

Heat Recovered kWt 1,430 1,430 1,552 1,552COP W/W 4.70 4.70 3.36 3.36Net Savings p.a. € p.a. 143k 755k 0 744kEstimated payback ≈ 3 years ≈ 1 year NA 1 – 2 years

Case 1: MVR to 150°C Case 2: MVR to 180°C

compressor, motor, inverter drive, instrumentation & control, auxiliaries and ancillaries

Example: MVR system return on investment


DRYficiency – EU project

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HighEFF, Research Center on Energy efficiency in the industry

Corner Stones: Energy Efficient

Processing Surplus Heat Utilization Industrial Clusters Education and Training

Research Areas: Methodologies Components Cycles Applications Society Case Studies

About 50 national and international partners Budget 420 MNOK over 8 years (2016-2024)


Large amounts of heat supply in the industry can be provided by high temperature heat pumps (HTHP)

HTHPs can reduce primary energy consumption and reduce emissions of greenhouse gases

Operating conditions may be very challenging Natural working fluid alternatives exist Systems and components are under development in the

HeatUp project and other projects

Thank you very much!

Conclusions


HeatUp more information

Contacts:[email protected]@sintef.no

http://www.sintef.no/projectweb/heatup/



http://www.sintef.no/projectweb/heatup/



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Svenska KVP 2016, Gøteborg, 2016-10-21 Høytemperatur …€¦ · Market and motivation HeatUp...

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